CN218083830U - Article and forming device for preparing article - Google Patents

Abstract

The utility model relates to an article and forming device of preparation article thereof. An article comprising a foamed member, the foamed member comprising a polymeric material; and a core embedded in the foaming member, the core including a first surface, a second surface and a sidewall, the foaming member covering at least a portion of the first surface and covering the entire sidewall and the entire second surface. A molding apparatus for preparing an article including a foaming member and a core includes a first mold, a second mold, and a mold cavity defined by the first mold and the second mold, the mold cavity including an inner wall of the first mold and a support member protruding from the inner wall; wherein the mold cavity is configured to receive the foaming member and the core, and the support member is configured to support the core in the mold cavity and prevent the core from contacting the inner wall of the first mold.

Description

Article and forming device for preparing article

Cross reference to related applications

The present application claims the chinese patent application No. 202111001038.7 at 8/30/2021, the U.S. patent application No. 17/831, 428 at 6/2/2022, the taiwan patent application No. 110130996 at 8/23/2021, and the taiwan patent application No. 110141372 at 11/5/2021, all of which are incorporated herein by reference.

Technical Field

The present invention relates to an article and a method for manufacturing the same, and more particularly, to an article having a foamed member and a core and a method for manufacturing the same.

Background

Articles comprising a foamed member and a core have many advantages such as high strength, low weight, impact resistance, thermal insulation, etc. The article may be made by bonding or interlocking the foam member and the core, thus exposing at least the entire surface of the core. Accordingly, there is still a need for improvements in article structures including foamed members and cores, and methods of making the same.

SUMMERY OF THE UTILITY MODEL

It is an object of the present disclosure to provide an article and a method of making the same.

According to an embodiment of the present disclosure, an article is disclosed. The article includes: a foam member comprising a polymeric material, and a core embedded in the foam member. The core includes a first surface, a second surface opposite to the first surface, and a sidewall between the first surface and the second surface, the foaming member covers at least a portion of the first surface and covers the entire sidewall and the entire second surface.

According to an embodiment of the present disclosure, a method of manufacturing an article is disclosed. The method comprises the following steps: providing a molding device, wherein the molding device comprises a first mold, a second mold corresponding to the first mold, and a supporting member protruding from the inner wall; disposing a core on the support member; and disposing the second mold over the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member. At least a portion of the first foam member contacts the core.

Drawings

Aspects of the disclosure are best understood from the following description when read with the accompanying drawing figures. It should be noted that the various features are not drawn to scale in accordance with standard practice in the industry. In fact, the dimensions of the various features may be arbitrarily expanded or reduced for clarity.

FIG. 1 is a schematic diagram illustrating an exemplary object according to an embodiment of the present disclosure.

Fig. 2 and 2A are schematic diagrams illustrating a portion of an exemplary article according to an embodiment of the present disclosure.

Fig. 3-6 are schematic cross-sectional views taken along line II-II' of fig. 1 and illustrating exemplary articles according to an embodiment of the present disclosure.

FIG. 7 is a flow chart illustrating a method of fabricating an article according to an embodiment of the present disclosure.

Fig. 8, 13, 14, 17-21 are schematic cross-sectional views illustrating exemplary operations of a method of fabricating an article according to an embodiment of the present disclosure.

Fig. 9-12 are schematic top views of a portion of an injection molding system for use in a method of manufacturing an article according to an embodiment of the present disclosure.

Fig. 15 and 16 are schematic views of a portion of an injection molding system 100 according to an embodiment of the present disclosure.

FIG. 22 is a schematic diagram illustrating an exemplary object in accordance with one embodiment of the present disclosure.

FIGS. 23-26 are schematic cross-sectional views illustrating exemplary operations of a method of fabricating an article according to an embodiment of the present disclosure.

FIGS. 27 and 28 are schematic diagrams illustrating an exemplary article according to an embodiment of the disclosure.

FIG. 29 is a schematic view of a portion of the injection molding system of FIG. 1 in accordance with one embodiment of the present disclosure.

FIG. 30 is an enlarged view of a portion of the injection molding system encircled by dashed lines in FIG. 29 according to an embodiment of the present disclosure.

Figure 31 is a graph illustrating the behavior of foaming dose versus minimum distance in a mixture according to one embodiment of the present disclosure.

FIG. 32 is a graph illustrating the behavior of blowing agent to polymer material ratio versus shortest distance to mixing rotor diameter in accordance with an embodiment of the present disclosure.

Detailed Description

The following description provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, forming a first feature on or over a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features are not in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Furthermore, spatially relative terms, such as below, beneath, above, over, and the like, may be used herein to describe one element or feature's relationship to another element(s) or feature(s) as illustrated. Such spatially relative terms encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Additionally, as used herein, the term "about" generally refers to within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, from the perspective of one skilled in the art, the term "about" means within an acceptable standard error of the mean. Other than in the operating/working examples, or where otherwise explicitly indicated, all numerical ranges, amounts, values and percentages set forth herein, such as amounts of material, durations, temperatures, operating conditions, quantitative ratios, and the like, are to be understood as modified in all instances by the term "substantially", "about" or "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and attached claims are approximations that may vary depending upon the desired properties. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges may be expressed herein as from one end point to the other end point or between two end points. Unless otherwise indicated, all ranges disclosed herein are inclusive of the endpoints.

FIG. 1 illustrates a schematic diagram of an object in accordance with an embodiment of the present disclosure. Fig. 2 and 2A are schematic diagrams illustrating an object core according to an embodiment of the present disclosure. The core of the article may have various configurations as shown in any of fig. 3-5. Fig. 3-5 are schematic cross-sectional views along line II-II' in fig. 1 and illustrate various configurations of articles according to an embodiment of the present disclosure. Referring to fig. 1 and 2, the article 20 includes a foam member 22 comprising a polymeric material and a core 21 embedded in the foam member 22. The core 21 improves the strength of the article 20. The shapes of the core 21 and the foaming member 22 may correspond to each other, and may be circular, oval, rectangular, square or other desired shapes in plan view, but are not limited thereto. In some embodiments, the article 20 is a portion of footwear or a semi-finished article of footwear. In some embodiments, the article 20 is an outsole of footwear. In some embodiments, the article 20 is a midsole of footwear. In some embodiments, the thickness of the article 20 is equal to or greater than 20mm. In some embodiments, the thickness of the article 20 is equal to or greater than 25mm.

In some particular embodiments, the foamed member 22 includes a polymeric material, such as Ethylene Vinyl Acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic Polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the foaming member 22 comprises a recyclable material. In some embodiments, the peripheral thickness of the foaming member 22 is equal to or greater than 20mm. In some embodiments, the peripheral thickness of the foaming member 22 is equal to or greater than 25mm. In some embodiments, the foaming member 22 further comprises a foaming agent. In some embodiments, the blowing agent may be any type of chemical or physical blowing agent known to those skilled in the art. In some embodiments, the blowing agent is a supercritical fluid. The supercritical fluid may include an inert gas, such as carbon dioxide or nitrogen in a supercritical state. In some embodiments, the foaming member 22 is made of a molding material that includes a polymeric material and a foaming agent. In some embodiments, the article 20 is free of adhesive.

In some embodiments, the core 21 includes a first surface 211, a second surface 212 opposite the first surface 211, and a sidewall 213 between the first surface 211 and the second surface 212. In some embodiments, the foaming member 22 covers at least a portion of the first surface 211, and covers the entire sidewall 213 and the entire second surface 212. In some embodiments, the foaming member 22 is in contact with at least a portion of the first surface 211 and is in contact with the entire sidewall 213 and the entire second surface 212. In some embodiments, a portion of the first surface 211 is exposed through the foaming member 22. In some embodiments, the markings 374 are disposed at and recessed into the foaming member 22. In some embodiments, a portion of the first surface 211 is exposed by the markings 374. In some embodiments, the mark 374 overlaps the core 21 as viewed from above.

In some embodiments, the article 20 is free of indicia 374 and the core 21 is surrounded by the foamed member 22. In some embodiments, the foaming member 22 contacts the entire first surface 211, the entire sidewall 213, and the entire second surface 212.

In some particular embodiments, the core 21 includes a polymeric material, such as Ethylene Vinyl Acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic Polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the core 21 is a non-foamed piece. In some embodiments, the core 21 includes recyclable materials. Additionally, in some embodiments, the core 21 is a foamed piece. In some embodiments, the foamed member 305 includes a polymeric material and a foaming agent. In some embodiments, the non-foamed member has a stiffness greater than the stiffness of the foamed member. In some embodiments, the core 21 and the foaming member 22 comprise the same material.

To enhance the bonding strength between the core 21 and the foaming member 22, in some embodiments, the surface area of the core 21 is increased by forming a pattern on the first surface 211 and/or the second surface 212, and at least a portion of the foaming member 22 conforms to the pattern. In some embodiments, the characteristics of the core 21 are affected by the pattern. The pattern may be distributed on the core 21 and is not limited to a specific type as long as the characteristics of the core 21 meet the actual needs. In some embodiments, at least one of the first surface 211, the second surface 212, and the sidewall 213 is a rough surface. In some embodiments, core 21 has a young's modulus ranging between 230 and 430kg/mm 2.

In some embodiments, referring to fig. 2A, core 21 includes two or more workpieces. In some embodiments, the core 21 includes a first layer 217 and a second layer 218 disposed over the first layer 217. Alternatively, in some embodiments, the first layer 217 is disposed on the second layer 218. In some embodiments, the first layer 217 is attached to the second layer 218. In some embodiments, the first layer 217 is a non-foamed member and the second layer 218 is a foamed member. In some embodiments, the first layer 217 and the second layer 218 comprise the same or different materials. In some embodiments, the first layer 217 is bonded directly to the second layer 218. In some embodiments, an adhesive is applied between the first layer 217 and the second layer 218 to bond the first layer 217 and the second layer 218.

In some embodiments, referring to fig. 2 and 3, the pattern is a via 214 extending between the first surface 211 and the second surface 212. In some embodiments, a portion of the foaming member 22 is disposed in the through hole 214. In some embodiments, a plurality of vias 214 extend between the first surface 211 and the second surface 212. In some embodiments, vias 214 are configured through core 21. In some embodiments, the density, size and shape of the through holes 214 are not limited as long as the characteristics of the core 21 meet the actual needs.

In some embodiments, referring to fig. 2 and 4, the pattern is a recess 215 recessed into the core 21 and disposed at the first surface 211. In some embodiments, a portion of the foaming member 22 is disposed in the recess 215. In some embodiments, the plurality of recesses 215 are disposed at the first surface 211, the second surface 212, and/or the sidewall 213 of the core 21. In some embodiments, the density, size, and depth of the recesses 215 are not limited, so long as the characteristics of the core 21 are consistent with practical needs.

In some embodiments, referring to fig. 2 and 5, the pattern is protrusions 216 protruding from the first surface 211. In some embodiments, the foaming member 22 surrounds the protrusion 216. In some embodiments, the plurality of protrusions 216 are disposed at the first surface 211, the second surface 212, and/or the sidewalls 213 of the core 21. In some embodiments, the density, size, and height of the protrusions 216 are not limited as long as the characteristics of the core 21 meet practical needs.

Fig. 6 is a schematic cross-sectional view of an article according to some embodiments of the present disclosure. In some embodiments, referring to fig. 6, a component 23 is disposed over the core 21 and the foaming member 22. In some embodiments, the component 23 is attached to and disposed above the foaming member 22. In some embodiments, a portion of the foaming member 22 is disposed between the element 23 and the core 21 such that the core 21 does not contact the element 23. In some embodiments, the component 23 is adjacent to the core 21. In some embodiments, first surface 211 of core 21 faces component 23. In some embodiments, component 23 is a sockliner, an upper, or any other suitable component of footwear.

FIG. 7 is a flow chart of a method 700 of fabricating an article according to some embodiments of the present disclosure. The method 700 includes several steps: step (701), providing a molding apparatus, wherein the molding apparatus includes a first mold, a second mold corresponding to the first mold, the first mold including an inner wall and a supporting member protruding from the inner wall; step (702) of disposing a core on the support member; step (703) disposing the second mold over the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; injecting (704) a first material into the mold cavity; and (705) foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member contacts the core.

To illustrate the concepts and methods 700 of the present disclosure, various specific embodiments are provided below. However, the present disclosure is not intended to be limited to the specific embodiments. In addition, components, conditions, or parameters that are illustrated in different specific embodiments can be combined or modified to form different combinations of the specific embodiments, as long as the components, parameters, or conditions that are used do not conflict. For ease of illustration, reference numerals having similar or identical functions and features are repeated among the various embodiments and figures. The various operations of the injection molding method and the articles formed thereby may have various configurations as shown in any of fig. 8, 13, 14 and 17-21. FIG. 22 is a schematic cross-sectional view of an article 20 manufactured by a method 700 illustrating some embodiments according to the present disclosure.

In some embodiments, the injection molding system 100 of step 701 of the method 700 according to some embodiments of the present disclosure is illustrated in fig. 8. In some embodiments, the method 700 of manufacturing the article 20 includes step 701, which includes providing a molding apparatus 30, wherein the molding apparatus 30 includes a first mold 33, a second mold 32 corresponding to the first mold 33. In some embodiments, the first mold 33 is a lower mold, and the second mold 32 is an upper mold. In some embodiments, the molding apparatus 30 includes a mold base 34 adjacent to the first mold 33 and the second mold 32. In some embodiments, the mold base 34 is attached to the first mold 33. In some embodiments, the molding device 30 is provided or received as shown in FIG. 8. In some embodiments, the molding device 30 is configured to form the article 20.

In some embodiments, first mold 33 and second mold 32 are spaced apart from each other during step 701. In some embodiments, the first mold 33 and the second mold 32 are complementary and separable from each other. In some embodiments, first mold 33 and second mold 32 are complementary to each other to define a mold cavity (not shown).

In some embodiments, the first mold 33 defines a lower mold cavity 331 and the second mold 32 defines an upper mold cavity 321. In some embodiments, the first mold 33 includes an inner wall 332 and a support member 37 protruding from the inner wall 332. In some embodiments, the inner wall 332 of the first mold 33 is curved.

In some embodiments, at least one feed port 35 is provided at the forming device 30. In some embodiments, the feed port 35 is disposed at the first die 33 or the second die 32. In some embodiments, the feed port 35 may be in communication with the upper mold cavity 321 or the lower mold cavity 331. For clarity and simplicity, FIG. 8 illustrates only one feed port 35 contained within a mold, but this example is intended to be illustrative only and not intended to be limiting on these embodiments. Those skilled in the art will readily appreciate that a mold may include one or more feed ports 35 in communication with either the upper mold cavity 321 or the lower mold cavity 331.

The feed port 35 is configured to receive molding material (not shown) into the upper mold cavity 321 and/or the lower mold cavity 331. In some embodiments, a plurality of feed ports 35 are provided at the forming device 30. The molding material may be fed into the molding device 30 through the feed inlet 35. In some embodiments, the molding material is injected into the upper mold cavity 321 and the lower mold cavity 331, and then the foaming member 22 is formed in the upper mold cavity 321 and the lower mold cavity 331 after a period of time. In some embodiments, the feed port 35 is disposed at the first die 33. In some embodiments, the feed port 35 may be disposed at the sidewall of the first mold 33 or at any other suitable location as long as the feed port 35 is in communication with the lower mold cavity 331. In some embodiments, rather than providing the feed port 35 at the first die 33, the first feed port 35 may be provided at the second die 32 to access the upper die cavity 321.

In some embodiments, a feed opening 351 is connected to feed port 35. In some embodiments, the feed opening 351 is configured to deliver molding material from the feed opening to the molding device 30. In some embodiments, a feed opening 351 is configured at the inner wall 332 of the first mold 33 for delivering molding material from the feed opening 35 into the lower mold cavity 331. In some embodiments, the feed opening 351 is disposed at the inner sidewall 333 of the first mold 33. In some embodiments, the feeding opening 351 is configured at the inner bottom wall 334 of the first mold 33. In some embodiments, feed openings 351 are disposed at inner wall 322 of second mold 32. In some embodiments, feed opening 351 is configured to be adjacent to and separate from support member 37. In some embodiments, feed inlet 35 is in communication with a plurality of feed openings 351. In some embodiments, a plurality of feed openings 351 are respectively connected to the feed ports 35. In some embodiments, the feed openings 351 may have different widths or diameters. The plurality of positions of the feed opening 351 are not particularly limited, and may be disposed at different regions of the inner wall 332 of the first mold 33 and the inner wall 322 of the second mold 32. In some embodiments, the end of feed inlet 35 that connects to upper mold cavity 321 and/or lower mold cavity 331 has a plurality of guide channels 352, wherein each guide channel 352 connects a corresponding feed opening 351 and feed inlet 35.

In some embodiments, mold base 34 includes an opening 341. Each of these openings 341 extends through the mold base 34. The mold base 34 can be fixed to the first mold 33 or the second mold 32 by screws, clamps, fastener devices, etc. In some embodiments, the material of the mold base 34 is the same as the material of the first mold 33. In some embodiments, the height H1 of the mold base 34 is greater than or equal to the height H2 of the first mold 33 or the second mold 32.

In some embodiments, the molding apparatus 30 further includes one or more pressure regulation systems 36. In some embodiments, the junction 367 may connect the lower mold cavity 331 or the upper mold cavity 321. In some embodiments, a plurality of joints 367 connect upper mold cavity 321 or lower mold cavity 331. In some embodiments, the junction 367 is configured to allow a fluid or gas to enter or exit the forming device 30. The position, shape and number of the engaging points 367 are not particularly limited and may be adjusted as needed. In some embodiments, each of these junctions 367 is a hole.

The pressure regulating system 36 may include a first gas conduit 361, a second gas conduit 362, a gas source 363, a first valve 364, a second valve 365, and a pressure sensing unit 366. In some embodiments, one end of the first gas conduit 361 is connected to the connection point 367, and the other end of the first gas conduit 361 is connected to the gas source 363. In some embodiments, the gas source 363 is configured to supply a fluid or gas, wherein a suitable fluid or gas may be supplied as desired; for example, the fluid or gas may be air, an inert gas, etc., but the present disclosure is not limited thereto. In some embodiments, one end of the first gas conduit 361 is coupled to the junction 367.

In some embodiments, the junction 367 is configured to supply gas or exhaust gas. A first valve 364 is disposed at the first gas conduit 361 and is configured to control whether gas from the gas source 363 enters the lower die cavity 331 and/or the upper die cavity 321 through the first gas conduit 361 and the junction 367. In some embodiments, when the first valve 364 is open and the second valve 365 is closed, fluid or gas is supplied to the lower mold cavity 331 and/or the upper mold cavity 321; when the first valve 364 is closed and the second valve 365 is open, at least a portion of the fluid or gas within the lower mold cavity 331 and/or the upper mold cavity 321 is vented.

In some embodiments, second gas conduit 362 is coupled to junction 367. Second valve 365 is disposed at second gas conduit 362 and is configured to control whether gas from lower die cavity 331 or upper die cavity 321 is vented through second gas conduit 362 via junction 367. In some embodiments, second gas conduit 362 is coupled to junction 367.

In some embodiments, one end of the second gas conduit 362 communicates with a space having a pressure less than the pressure in the lower mold cavity 331 or the upper mold cavity 321; for example, an external environment or a negative pressure space; however, the present disclosure is not so limited. In some embodiments, the first valve 364 and the second valve 365 are not open at the same time.

The pressure sensing unit 366 is configured to sense a pressure within the lower mold cavity 331 or the upper mold cavity 321. The pressure sensing unit 366 is not limited to any particular type as long as it can sense pressure and provide pressure information after sensing the pressure within the lower mold cavity 331 or the upper mold cavity 321. The pressure regulating system 36 changes the conditions under which the gas exits/enters from/into the lower mold cavity 331 or the upper mold cavity 321 according to the pressure information, thereby regulating the pressure within the lower mold cavity 331 or the upper mold cavity 321, so that the composite material thus obtained has a desired predetermined shape and properties.

In some embodiments, a pressure sensing unit 366 is disposed within the lower mold cavity, the upper mold cavity 321, the first gas conduit 361, or the second gas conduit 362. In some embodiments, the pressure sensing unit 366 is disposed within the lower mold cavity 331 and the upper mold cavity 321, and is remote from the feed opening 351. In some embodiments, pressure regulation system 36 has a plurality of pressure sensing units 366. The number and position of the plurality of pressure sensing units 366 are not particularly limited, for example, they may be disposed at and spaced apart from the inner walls 322, 332 of the first and second molds 33, 32, and/or at any position in the first gas conduit 361, and/or at any position in the second gas conduit 362; however, the present disclosure is not so limited.

In some embodiments, support members 37 are used to support core 21 and prevent core 21 from contacting inner wall 332 of first mold 33. The core 21 may be disposed on the support member 37 and then the molding material filled into the molding device 30 may contact the first surface 211, the second surface 212, and the sidewall 213 of the core 21. In some embodiments, the top surface of the support member 37 has a surface area that is less than the surface area of the first surface 211 of the core 21. In some embodiments, the support member 37 and the feed opening 351 are disposed at the inner wall 332 of the first mold 33. The support member 37, the feed opening 351 and the junction 367 are separated from each other.

In some embodiments, the supporting member 37 includes a plurality of supporting units 371, 372, 373 protruding from the inner wall 332. The supporting units 371, 372, 373 are separated from each other. The positions and the number of the supporting units 371, 372, 373 are not particularly limited, and may be adjusted as needed, for example, disposed at different regions of the inner wall 332 of the first mold 33. In some embodiments, the supporting units 371, 372, 373 are disposed at the inner bottom wall 334 of the first mold 33 and protrude therefrom. In some embodiments, at least two of the support units 371, 372, 373 are disposed on opposite sides of the inner wall 332 of the first mold 33. In some embodiments, the number of bonding points 367 is greater than the number of support units 371, 372, 373. The height of each of these supporting units 371, 372, 373 may be the same or different as long as the core 21 can be configured on the supporting units 371, 372, 373. In some embodiments, the height of each of the supporting units 371, 372, 373 is the same.

In some embodiments, each of the supporting units 371, 372, 373 is disposed adjacent to the corresponding feeding opening 351 when viewed in a cross-sectional view. In some embodiments, each of the supporting units 371, 372, 373 is disposed adjacent to the corresponding joint 367 when viewed in a cross-sectional view. In some embodiments, one of the supporting units 371, 372, 373 is arranged between the corresponding feeding opening 351 and the corresponding bonding point 367. In some embodiments, one of the supporting units 371, 372, 373 is disposed adjacent to the corresponding feeding opening 351 and the corresponding junction 367. In some embodiments, one of the feeding openings 351 is configured between the corresponding junction 367 and the corresponding support unit 371.

In some embodiments, to maintain a temperature differential between the vent channel 50 and the molding device 30, the injection molding system 100 further includes an insulator 70 disposed between the vent channel 50 and the molding device 30. In some embodiments, an insulator 70 is disposed between the vent passage 50 and the mold base 34. In some embodiments, an insulator 70 is disposed at the mold base 34. In some embodiments, an insulator 70 is disposed between the outlet 51 and the feed port 35.

The discharge passage 50 may extend into the insulator 70 so as to be partially surrounded by the insulator 70. In some particular embodiments, the insulator 70 includes an opening 71 configured to receive the vent passage 50. Opening 71 of insulator 70 is aligned with opening 341 of die base 35 and feed gap 35. The opening 71 extends through the insulator 70. The insulator 70 may be secured to the mold base 34, such as by screws. The insulator 70 may comprise a non-thermally conductive material, such as fiberglass. The insulator 70 may be constructed entirely of a non-metallic material. In some embodiments, the insulator 70 has a melting point that is substantially higher than the temperature of the mixture flowing through the discharge passage 50. In some embodiments, the melting point of the insulator 70 is substantially greater than 180 ℃.

Fig. 9-12 are schematic top views of a portion of the injection molding system 100 of step 701 of the method 700 according to some embodiments of the present disclosure. The portions may each be the same or different in size and shape from each other, and may be circular, oval, rectangular, square, curved, ribbon-like, or other desired shape in plan view, but are not limited thereto. In some embodiments, referring to fig. 9, the supporting units 371, 372, 373 have similar shapes. In some embodiments, each of the supporting units 371, 372, 373 has a bar shape in a top view. Further, a distance D1 between the supporting unit 371 and the supporting unit 372 and a distance D2 between the supporting unit 372 and the supporting unit 373 may be the same or different. In some embodiments, distance D1 is equal to distance D2. In some embodiments, distance D1 is not equal to distance D2. The length L1 of the supporting unit 371, the length L2 of the supporting unit 372, and the length L3 of the supporting unit 373 may be the same as or different from each other. The lengths of L1, L2, L3 are not limited as long as the core 21 can be arranged on the support member 37.

In some embodiments, referring to fig. 10, the shapes of the supporting units 371, 372, 373 are different. In some embodiments, the supporting unit 372 is disposed between the supporting unit 371 and the supporting unit 373. The shape of the supporting unit 371 is similar to that of the supporting unit 373, and the shape of the supporting unit 372 is different from that of the supporting unit 371. In some embodiments, the support units 371, 372, 373 are arranged in a column. In some embodiments, referring to fig. 11, the supporting units 371, 372, 373 are configured in an arc shape. In some embodiments, referring to fig. 12, at least one of the supporting units 371, 372, 373 has a curved shape. In some embodiments, at least one of the feeding openings 351 and one of the junctions 367 are disposed between the support unit 371 and the support unit 373.

In some embodiments, the method 700 further includes providing an extrusion system 10 configured to produce modeling material (not shown), and providing a vent channel 50 communicable with the extrusion system 10 and including a remote outlet 51 configured at the extrusion system 10 and configured to vent the modeling material. In some embodiments, the inlet 35 of the forming device 30 may be relatively engaged with the outlet 51.

In some embodiments, the extrusion system 10 and the discharge passage 50 are disposed adjacent the feed inlet 35 of the forming device 30. The molding device 30 is configured to receive molding material from the outlet 51 of the discharge passage 50.

In some embodiments, the method 700 of manufacturing an article includes step 702, which includes supporting the core 21 on the support member 37. In some embodiments, referring to fig. 13, the core 21 is disposed on the supporting units 371, 372, 373. In some embodiments, the core 21 is disposed at the lower mold cavity 331. In some embodiments, the first surface 211 of the core 21 is a contact support unit 37. In some embodiments, the supporting unit 37 is disposed between the core 21 and the inner wall 332 of the first mold 33. Due to the support unit 37, the core 21 arranged within the forming device 30 may not cover the feed opening 351 and the junction 367.

In some embodiments, referring back to fig. 2A and 13, step 702 includes disposing the first layer 217 of the core 21 over the support member 37 and disposing the second layer 218 of the core 21 over the first layer 217. In some embodiments, method 700 includes disposing first layer 217 and second layer 218 in forming device 30 layer-by-layer. In some embodiments, the second layer 218 is attached to the first layer 217. In some embodiments, the method 700 includes bonding the first layer 217 to the second layer 218, and simultaneously disposing the first layer 217 and the second layer 218 into the molding apparatus 30.

In some embodiments, method 700 of manufacturing an article includes step 703 of disposing second mold 32 over first mold 33 to form a mold cavity 31 defined by first mold 33 and second mold 32, wherein core 21 is disposed in mold cavity 31. In some embodiments, referring to FIG. 14, the molding device 30 is in a closed position. In some embodiments, when the molding device 30 is in the closed configuration, the mold cavity 31 is formed. In some embodiments, when molding apparatus 30 is closed, first mold 33 is in close engagement with second mold 32.

In some embodiments, the method 700 includes engaging the outlet 51 with the feed inlet 35 of the molding apparatus 30.

In some embodiments, referring back to fig. 8 and 13, at the beginning of steps 701 and 702, the extrusion system 10 and the discharge passage 50 are remote from the molding apparatus 30. In some embodiments, the discharge passage 50 is moved to a first position adjacent the molding device 30 before the outlet 51 engages the feed port 35 of the molding device 30. In some embodiments, the discharge passage 50 has been moved to a first position adjacent the molding device 30. In the first position, the vent passage 50 is aligned with the opening 341 of the mold base 34 of the molding device 30. In some embodiments, the distance between the outlet 51 and the mold base 34 is greater than 0. In some embodiments, in the first position, vent channel 50 is aligned with opening 71 of insulator 70 and opening 341 of mold base 341.

In some embodiments, referring to FIG. 14, after the discharge passage 50 is aligned with the opening 341, the discharge passage 50 is moved toward the molding device 30, received by the opening 341 of the mold base 34, and the outlet 51 is butted against the feed port 35. In some embodiments, the vent channel 50 moves toward the molding device 30 and is received by the opening 341 of the mold base 34. In some embodiments, the vent passage 50 moves toward the molding device 30, being received by the opening 71 of the insulator 70 and the opening 341 of the mold base 34.

After the outlet 51 is butted against the inlet port 35, the outlet 51 and the inlet port 35 form a molding material flow path so that the discharge passage 50 can communicate with the mold cavity 31 through the inlet port 35. The outlet 51 must be tightly engaged with the feed port 35 to prevent molding material from leaking out of the molding apparatus 30.

In some embodiments, the method 700 includes securing the vent passage 50 to the molding device 30. In some embodiments, the support device 40 applies a force to prevent the extrusion system 10 from separating from the molding device 30.

In some embodiments, when the extrusion system 10 injects the molding material into the molding device 30, the molding device 30 may generate a reaction force opposite to the injection direction, and the reaction force may be transmitted to the discharge passage 50 and the extrusion system 10, such that the discharge passage 50 tends to separate from the molding device 30. In some embodiments, the support device 40 provides support against a reaction force opposite the direction of implantation.

In some embodiments, the vent passage 50 is secured to the molding device 30 by engaging a first component 41 of the support device 40 with respect to a second component 42 of the support device 40, wherein the first component 41 protrudes from the extrusion system 10 and the second component 42 is disposed on the molding device 30. In some embodiments, the support device 40 provides a force after engagement to prevent the drain chute 50 from separating from the molding device 30.

Fig. 15 is a schematic diagram of a portion of an injection molding system 100 in accordance with an embodiment of the present disclosure. In some embodiments, referring to fig. 15, the support device 40 includes a first component 41 and a second component 42 configured to engage with each other, wherein the first component 41 protrudes from the extrusion system 10 or the discharge channel 50, and the second component 42 is configured on the forming device 30, although the disclosure is not limited thereto. In some embodiments, the first and second assemblies 41, 42 may be clamped to each other; for example, the second component 42 is configured to receive the first component 41.

In some embodiments, the support device 40 is disposed adjacent to the mold cavity 31 of the molding device 30. In some embodiments, first assembly 41 is disposed on discharge passage 50, and second assembly 42 is disposed on forming device 30. In some embodiments, the second component 42 is disposed on the mold base 34 of the molding apparatus 30. In some embodiments, the first component 41 is part of the extrusion system 10 or the vent channel 50, and the second component 42 is part of the molding apparatus 30. In some embodiments, the first assembly 41 is part of the extrusion system 10 and is disposed adjacent to the discharge passage 50, and the second assembly 42 is disposed on or faces the die base 34 of the molding apparatus 30. In some embodiments, the first and second components 41, 42 may engage each other to tightly engage the vent passage 20 with the mold base 34 of the molding apparatus 30.

In some embodiments, to prevent separation of the compression system 10 and molding device 30 during injection, the engaged first component 41 is forced against the second component 42. The force is equal to or greater than a threshold value. The threshold value may be adjusted based on the pressure within the mold cavity 31 and the diameter of the outlet 51 or based on other factors.

The position and number of the first members 41 may be adjusted as needed, and are not particularly limited. The position and number of the second members 42 may also be adjusted as needed, without particular limitation. In some embodiments, the position and number of the second components 42 correspond to the position and number of the first components 41. In some embodiments, the first component 41 may be disposed at any suitable location on the discharge passage 50, and the second component 42 may be disposed at any suitable location on the molding device 30. In some embodiments, the second assembly 42 is disposed adjacent to the upper mold 32.

Fig. 16 is a schematic view of a portion of an injection molding system 100 according to an embodiment of the present disclosure. In some embodiments, referring to fig. 16, the support device 40 can be in one of two states, namely, a locked state and an unlocked state. In the unlocked state, the first component 41 enters the corresponding second component 42, but is not yet locked by the second component 42. In other words, when the support device 40 is in the unlocked state, the first assembly 41 is still extractable from the second assembly 42. In the locked state, the first component 41 enters and is locked with the corresponding second component 42, so that the first component 41 cannot exit from the second component 42. Fig. 16 illustrates the support device 40 in a locked state. The support device 40 may be operated and controlled manually or automatically. The support device 40 can be manually or automatically switched between the two states.

In some embodiments, the first assembly 41 is rotationally fixed to the extrusion system 10. In some embodiments, the first component 41 includes an elongated portion 411 and an arm portion 412. The elongated portion 411 and the arm portion 412 are rotatable in the direction indicated by arrow a. The elongated portion 411 is fixed to the extrusion system 10 and extends in the first direction Z towards the upper die 32. The arm portion 412 is coupled to the elongated portion 411 and extends in a second direction X substantially perpendicular to the first direction Z, or in a third direction Y substantially perpendicular to the first direction Z. In some embodiments, first component 41 has an inverted T-shape. After the first member 41 enters the second member 42, the supporting device 40 is changed from the unlocked state to the locked state by rotating the arm portion 412 of the first member 41. In some embodiments, the first assembly 41 is locked with the second assembly 42 by rotating the arm portion 412 of the first assembly 41 about 90 degrees. Fig. 16 illustrates the arm portion 412 locked with the second assembly 42 after rotating the arm portion 412 about 90 degrees. Thus, the support device 40 is in the locked state and the discharge channel 20 is in close engagement with the molding device 30 and thus the mixture can begin to be injected into the molding device 30 from the extrusion system 10 and the discharge channel 50.

In some embodiments, referring to fig. 14-16, the discharge passage 50 secures the discharge passage 20 to the molding device 30 by bringing the support device 40 into a locked state, such as relative to the second assembly 42 of the support unit 40 and rotating the first assembly 41 of the support device 40 therein, while engaging the outlet 51 with the feed port 35. In some embodiments, when the outlet 51 is docked to the feed port 35, the first assembly 41 enters the second assembly 42 and then locks with the second assembly 42. In some embodiments, the discharge channel 50 is fixed to the molding device 30 by rotating the elongated portion 411 and the arm portion 412 of the first component 41 of the support device 40, the elongated portion 411 is fixed to the extrusion system 10 and extends in a first direction Z towards the molding device 30, and the arm portion 412 is coupled to the elongated portion 411 and extends in a second direction X different from the first direction Z.

In some embodiments, referring to FIG. 17, the method 700 further includes injecting a gas G into the mold cavity 31 via a pressure regulation system 36 coupled to the mold cavity 31 until the mold cavity 31 is sensed to have a first predetermined pressure prior to injecting the molding material into the mold cavity 31. In some embodiments, gas G is injected into mold cavity 31 through first gas conduit 361. In some embodiments, gas G is any suitable gas, depending on the need; for example, air; however, the present disclosure is not so limited. In some embodiments, the pressure within the mold cavity 31 of the molding device 30 is adjusted to a first predetermined pressure after the outlet 51 and the feed port 35 are engaged. After the molding device 30 has the first predetermined pressure, injection is started.

In some embodiments, the pressure sensing unit 366 senses the pressure in the mold cavity 31 as atmospheric pressure. In some embodiments, first valve 364 has been opened so that gas G is injected into mold cavity 31 through first gas conduit 361. In some embodiments, when the feed port 35 is closed, gas G is injected into the mold cavity 31 through the pressure regulation system 36. In some embodiments, gas G is injected into mold cavity 31 through feed port 35.

In some embodiments, the pressure in mold cavity 31 is continuously sensed during the process of injecting gas G into mold cavity 31. In some embodiments, the pressure sensing unit 366 continuously senses the pressure within the mold cavity 31 and injects the gas G into the mold cavity 31 until sensing that the mold cavity 31 has a first predetermined pressure; then, the first valve 364 and the second valve 365 of the pressure regulating system 36 have been closed, and the injection of the gas G into the mold cavity 31 is stopped. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

In some embodiments, prior to step 704, mold cavity 31 has a first predetermined pressure and both first valve 364 and second valve 365 of pressure regulation system 36 are closed.

In some embodiments, method 700 includes step 704, which includes injecting a first material M1 into mold cavity 31. In some embodiments, the modeling material made by the extrusion system 10 is the first material M1. The first material M1 comprises a polymeric material and a blowing agent. In some embodiments, referring to fig. 18, the first material M1 is injected into the mold cavity 31 through the outlet 51 and the feed port 35. In some embodiments, step 704 includes injecting the first material M1 from the discharge channel 50 into the mold cavity 31 through the outlet 51 and the feed opening 35. In some embodiments, the vent channel 50 is at least partially surrounded by the molding device 30 when the first material M1 is injected.

In some embodiments, at least a portion of the first material M1 is disposed between the inner wall 332 of the first mold 33 and the core 21. In some embodiments, at least a portion of the first material M1 is disposed between the supporting units 371, 372, 373. In some embodiments, at least a portion of the first material M1 is disposed in the recess 215 or the through-hole 214 of the core 21. In some embodiments, at least a portion of the first material M1 surrounds the protrusion 216 of the core 21.

In some embodiments, in step 704, during the injection of the first material M1 into the mold cavity 31 of the molding device 30, the pressure in the mold cavity 31 is rapidly changed, and the pressure sensing unit 366 continuously senses the pressure in the mold cavity 31. In some embodiments, the first material M1 is injected into the mold cavity 31 of the molding device 30 from the feed opening 35, and a first predetermined pressure is applied to the first material M1. In some embodiments, the first material M1 and the gas G are disposed in the mold cavity 31, and the first material M1 will expand and foam in the mold cavity 31.

In some embodiments, the first material M1 is injected into the mold cavity 31 of the molding device 30 from the feed opening 35, thereby increasing the pressure within the mold cavity 31. In some embodiments, the pressure within the mold cavity 31 of the molding device 30 is raised above a first predetermined pressure. In some embodiments, the pressure within the mold cavity 31 of the molding device 30 is increased from a first predetermined pressure to a second predetermined pressure.

In some embodiments, after the first material M1 is injected into the mold cavity 31 having the first predetermined pressure, the pressure within the mold cavity 31 is increased, and thus, the setting of the second predetermined pressure ensures that the mold cavity 31 is maintained within a suitable pressure range. In some embodiments, injection of first material M1 into mold cavity 31 is stopped when mold cavity 31 reaches a second predetermined pressure.

In some embodiments, the injection of the first material M1 into the mold cavity 31 having the first predetermined pressure only lasts for less than 1 second. In some embodiments, since the mold cavity 31 has the first predetermined pressure, the filling completion duration of the first material M1 may be less than 0.5 seconds. During this injection or when the injection is completed, the pressure sensing unit 366 instantaneously senses the pressure within the mold cavity 31 and provides pressure information so that the pressure regulating system 36 can adjust the pressure within the mold cavity 31 according to the pressure information, and thus can maintain the pressure within the mold cavity 31 within a predetermined pressure range.

In some embodiments, the temperature of the vent passage 50 is higher than the temperature of the molding apparatus 30 during the injection process. In some embodiments, an insulator 70 is used to maintain the temperature differential.

In some embodiments, referring to fig. 19, in step 705, the method 700 includes foaming the first material M1 to form the first foaming member 221. At least a part of the first foaming member 221 is the contact core 21. In some embodiments, at least a portion of the foaming member 221 is in contact with at least a portion of the first surface 211 and the entire sidewall 213 and the entire second surface 212 of the core 21. In some embodiments, the first surface 211 includes a first portion that contacts the first foaming member 221 and a second portion that contacts the support member 37.

In some embodiments, at least a portion of the first foaming member 221 is disposed between the inner wall 332 of the first mold 33 and the core 21. In some embodiments, at least a portion of the first material M1 is disposed between the supporting units 371, 372, 373. In some embodiments, at least a portion of the first foaming member 221 is disposed in the recess 215 or the through hole 214 of the core 21. In some embodiments, at least a portion of the first foaming member 221 surrounds the protrusion 216 of the core 21. In some embodiments, the article 20-1 is formed after the first foaming member 221 is formed. In some embodiments, the article 20-1 includes a core 21 and a first foaming member 221.

In some embodiments, the method 700 further includes retracting the support member 37 into the first mold 33 or removing the support member 37 from the mold cavity 31 during or after injecting the first material M1. In some embodiments, at least one of the support units 371, 372, 373 is retracted or removed after the first foaming member 221 is foamed. In some embodiments, the mark 374 is formed on the first foaming member 221 after the support member 37 is retracted or removed. In some embodiments, the mark 374 is formed at a position corresponding to the position of the support member 37. In some embodiments, after the support units 371, 372, 373 are retracted or removed, marks 374, 375, 376 are formed at positions corresponding to the positions of the support units 371, 372, 373, respectively. In some embodiments, the article 20-1 includes indicia 374, 375, 376. In some embodiments, the item 20-1 is free of markings 374, 375, 376. The first foaming member 221 of the article 20-1 surrounds the core 21. In some embodiments, the article 20-1 may be further removed from the forming device 30.

In some embodiments, the second portion of the first surface 211 of the core 21 is exposed through the mark 374, and the feed opening 351 is disposed proximate the mark 374. In some embodiments, each of the feed openings 351 is configured proximate to a corresponding one of the markings 374, 375, 376.

In some embodiments, method 700 further includes venting gas G from mold cavity 31 to reduce the pressure in mold cavity 31 to a third predetermined pressure. In some embodiments, a portion of the gas G is vented from the mold cavity 31 after the gas G is injected into the mold cavity 31. In some embodiments, during step 705, gas G is vented from mold cavity 31 through pressure regulation system 36 in less than 1 second while first material M1 foams in mold cavity 31. Due to the gas G venting, the first material M1 in the mould cavity 31 may have a lower density after the foaming process. In some embodiments, gas G is exhausted from die cavity 31 through junction 367. In some embodiments, the gas G is vented from the mold cavity 31 during or after the foaming process of the first material M1 in the mold cavity 31. In some embodiments, the pressure in the mold cavity 31 is reduced from the second predetermined pressure.

In some embodiments, when the pressure sensing unit 366 senses that the pressure in the mold cavity 31 is greater than the second predetermined pressure, a portion of the gas G in the mold cavity 31 is vented until the pressure within the mold cavity 31 is within a predetermined pressure range. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, second valve 365 is open and a portion of the gas within mold cavity 31 is vented through second gas conduit 362.

In some embodiments, referring to fig. 20, the method 700 further includes injecting a second material M2 into the mold cavity 31 after removing or retracting the support member 37. In some embodiments, the ratio of polymeric material to blowing agent in the first material M1 is substantially equal to the ratio of polymeric material to blowing agent in the second material M2. In some embodiments, the composition of the first material M1 is similar to the composition of the second material M2. In some embodiments, the core 21 is surrounded by the first material M1 and the second material M2.

In some embodiments, the modeling material made by the extrusion system 10 is the second material M2. In some embodiments, the second material M2 is injected into the mold cavity 31 through the outlet 51 and the feed opening 35. In some embodiments, the second material M2 is injected from the discharge channel 50 into the mold cavity 31 through the outlet 51 and the feed opening 35. In some embodiments, the vent channel 50 is at least partially surrounded by the molding device 30 during the injection of the second material M2.

In some embodiments, the deployed position of the second material M2 corresponds to the position of the support member 37. In some embodiments, the second material M2 is disposed in the mark 374. In some specific embodiments, after the marks 374, 375, 376 are formed at respective positions corresponding to the positions of the supporting units 371, 372, 373, respectively, the second material M2 is disposed in the marks 374, 375, 376. In some embodiments, at least a portion of the second material M2 is in contact with the first surface 211 of the core 21. In some embodiments, the first foaming member 221 surrounds the second material M2. In some embodiments, at least a portion of the second material M2 contacts the first foaming member 221.

In some embodiments, the method 700 further includes foaming the second material M2 to form the second foamed member 222. In some embodiments, the core 21 is surrounded by the first foaming member 221 and the second foaming member 222. In some embodiments, at least a portion of the second foaming member 222 is in contact with the first surface 211 of the core 21. In some embodiments, the first foaming member 221 surrounds the second foaming member 222. In some embodiments, at least a portion of the second foaming member 222 is in contact with the first foaming member 221. In some embodiments, the article 20-2 is formed after forming the first and second foaming members 221, 222. In some embodiments, the article includes a core 21, a first foamed member 221, and a second foamed member 222.

In some embodiments, after forming the second foaming member 222, the second mold 32 is moved away from the first mold 33 and the discharge passage 50 is disengaged from the molding device 30 and extracted therefrom, as shown in fig. 21. The outlet 51 is free of the feed inlet 35. The forming device 30 is changed from the closed configuration (fig. 17 to 20) to the open configuration (fig. 21).

In some embodiments, referring to FIG. 22, after the article 20-2 is formed, the article 20-2 is then removed from the first mold 33. In some embodiments, the object 20-2 is picked up manually by a human hand, or automatically by a robot, robotic arm, gripper, or the like.

In some embodiments, method 700 further includes disposing component 23 within opening 322 of second mold 32 prior to injecting first material M1. Fig. 23-26 are schematic cross-sectional views of the injection molding system 200 illustrating steps 701-705 of a method 700 according to some embodiments of the present disclosure. Fig. 27 and 28 are schematic cross-sectional views of an article 20-3 being manufactured by a method 700 illustrating some embodiments according to the present disclosure.

In some embodiments, referring to fig. 23, second mold 32 is in another configuration that includes opening 322. In some embodiments, second mold 32 includes an opening 322 configured relative to first mold 33. In some embodiments, referring to FIG. 24, a component 23 may be received by and disposed within opening 322. In some embodiments, mold cavity 31 is defined by first mold 33, second mold 32, and assembly 23, as shown in fig. 25. In some embodiments, the first material M1 is injected into the mold cavity 31 between the component 23 and the inner wall 332 of the first mold 33, as shown in fig. 26, similar to the operation shown in fig. 18. During the formation of the first foaming member 221, the assembly 23 is in contact with the first material M1. Thus, the article 20-3 is manufactured as shown in FIG. 26. In some embodiments, the article 20-3 is a product or semi-product comprising the assembly 23 and a first foaming member 221, at least a portion of the first foaming member 221 being disposed between the core 21 and the assembly 23. In some embodiments, component 23 is a sockliner, an upper, or any other suitable component of footwear.

In some embodiments, referring to FIG. 27, the article 20-3 further includes a mark 374. In some embodiments, the article 20-3 further includes a plurality of markings 374, 375, 376. In some embodiments, referring to FIG. 28, the article 20-3 further includes a second foamed member 222 formed of a second material M2.

In some embodiments, the method 700 includes injecting the first material M1 and the second material M2 from the extrusion system 10 into the discharge channel 50. Fig. 29 is a schematic view of an extrusion system in accordance with aspects of the present disclosure in some embodiments. The extrusion system 10 includes a melting unit 120 and a mixing unit 130. In some embodiments, the extrusion system 10 includes a melting unit 120, a mixing unit 130, a foamer supply unit 140, an injection unit 150, a first flow control element 161, a second flow control element 162, and a monitoring module 180.

In some embodiments, referring to fig. 29, the melting unit 120 is configured to deliver a polymeric material. In some embodiments, the melting unit 120 includes a pressurized box 121, a first feed channel 122, a first discharge channel 123, and a pushing member 124. In some embodiments, the melting unit 120 further includes a hopper 125.

In some embodiments, the first feeding passage 122 and the first discharging passage 123 are respectively disposed at both ends of the pressurizing cartridge 121. In some embodiments, the first feeding channel 122 communicates with the interior space 1211 of the pressurization cartridge 121, and the first discharge channel 123 communicates with the exterior space of the pressurization cartridge 121, wherein the first feeding channel 122 is configured for conveying the polymeric material to the interior space 1211 of the pressurization cartridge 121. In some embodiments, the feed hopper 125 is configured to deliver polymeric material through the first feed channel 122 to the interior space 1211 of the pressurized cartridge 121.

Pushing member 124 is configured to convey polymeric material from first feed channel 122 to first discharge channel 123. In some embodiments, the pushing member 124 is disposed in the interior 1211 of the pressure cartridge 121. In some embodiments, a pushing member 124 is disposed in the interior space 1211 of the pressurization cartridge 121 between the first feeding channel 122 and the first discharge channel 123 and is used to push the polymeric material toward the first discharge channel 123. In some embodiments, the pushing member 124 may rotate relative to the pressurization cartridge 121. In some embodiments, polymeric material is delivered from first feed channel 122 to first discharge channel 123 by rotation of pushing member 124. In some embodiments, the pushing member 124 cannot move in a direction parallel to the longitudinal axis of the pressure magazine 121.

In some embodiments, the length of the pushing member 124 extends along the length of the pressure pocket 121, and the ratio of the shortest distance D5 between the inner sidewall 1212 of the pressure pocket 121 and the pushing member 124 to the diameter D6 of the pushing member 124 is between about 1:1500 to about 1:4500, and the polymer material may be uniformly melted by the melting unit 120. In some embodiments, the shortest distance D5 between the inner sidewall 1212 of the pressurization pocket 121 and the pushing member 124 is substantially equal to or less than 0.3mm. In some embodiments, the shortest distance D5 between the inner sidewall 1212 of the pressurization cartridge 121 and the pushing member 124 is between 0.01 and 0.05 mm.

Mixing unit 130 is configured to receive the polymeric material from melting unit 120 and to mix the polymeric material with a blowing agent to form a mixture of the polymeric material and the blowing agent. The mixing unit 130 includes a hollow mixing box 131, a second feeding channel 132, a second discharging channel 133, and a mixing rotor 134.

The second feeding channel 132 and the second discharging channel 133 are respectively disposed at both ends of the mixing box 131. In some embodiments, the second feed channel 132 is configured to convey polymeric material. In some embodiments, the second discharge channel 133 is configured to deliver discharge of the mixture.

The mixing rotor 134 is configured to mix the polymeric material with the blowing agent to form a mixture within the mixing cartridge 131. In some embodiments, the mixing rotor 134 is disposed in the mixing box 131. In some embodiments, a mixing rotor 134 is disposed in the mixing box 131 between the second feeding channel 132 and the second discharging channel 133 to stir the mixture in the mixing box. The mixing rotor 134 may rotate to mix the polymeric material with the blowing agent and convey the mixture of polymeric material and blowing agent from the second feed channel 132 to the second discharge channel 133. In some embodiments, the mixing rotor 134 cannot move in a direction parallel to the longitudinal axis of the mixing cartridge 131.

In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing cartridge 131, and the ratio of the distance D3 between the inner sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is between about 1:1500 to about 1:4500, and the mixture can be uniformly prepared by the extrusion system 10. In some embodiments, the mixture may be divided into multiple portions, and the ratio of blowing agent to polymeric material for each portion of the mixture prepared by the extrusion system 10 is substantially constant. In some embodiments, the ratio of polymeric material to blowing agent in the first portion of the mixture is substantially equal to the ratio of polymeric material to blowing agent in the second portion of the mixture. In some embodiments, the shortest distance D3 between the interior sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is substantially equal to or less than 0.3mm. In some embodiments, the shortest distance D3 between the inner sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is between 0.01 and 0.09 mm.

FIG. 30 is an enlarged view of a portion of an extrusion system in accordance with aspects of the present disclosure in some embodiments. In order to uniformly mix the melted polymer material and the foaming agent in the mixing box 131, in some embodiments, referring to fig. 29 and 30, the mixing rotor 134 further includes a cylindrical body 1341 rotatably disposed in the mixing box 131 and a concave portion 1342 annularly disposed on the periphery of the cylindrical body 1341. Therefore, when the cylindrical body 1341 rotates, the polymer material and the foaming agent are agitated by the recess 1342, thereby obtaining a desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the recess 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131.

In some embodiments, when the shortest distance D3 is the shortest distance between the recess 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131, the shortest distance D3 is between 0.01 and 0.09 mm. In some embodiments, the diameter D4 of the mixing rotor 134 is in a range between 45 to 75 mm. Table 1 lists the shortest distance D3, the diameter D4, and the corresponding ratio of the shortest distance D3 between the recess 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131 to the diameter D4 of the mixing rotor 134.

TABLE 1

In some embodiments, when the shortest distance D3 is substantially less than 0.01mm, the predetermined amount of blowing agent in the mixture is substantially greater than 0.8/cm ³ As shown in fig. 31. In some embodiments, if the blowing agent in the predetermined amount of the mixture is substantially greater than 0.8/cm ³ The density of the bubbles in the predetermined amount of mixture after foaming is significantly greater than 180000/cm ³ 。

In some embodiments, when the ratio of the shortest distance D3 to the distance D4 is between 1:1500 and 1:4500, the uniformity of blowing agent to polymeric material is optimized. In other words, the mixing of the blowing agent and the polymeric material by the mixing rotor 134 is even and uniform. In some embodiments, when the ratio of the shortest distance D3 to the distance D4 is between 1:1500 and 1:4500, as shown in fig. 32, the ratio of blowing agent to polymeric material in the predetermined amount of mixture is in the range of 4:1 to 3: 1. In some embodiments, the ratio of blowing agent to polymeric material in the predetermined amount of mixture is about 1:1. in some embodiments, if the ratio of blowing agent to polymeric material in the predetermined amount of mixture is between 4:1 and 3:1, then after foaming, the ratio of bubbles to polymeric material in the predetermined amount of mixture is also between 4:1 and 3: 1. In some embodiments, after foaming, the ratio of bubbles to polymeric material in the predetermined amount of mixture is about 4:1.

in some embodiments, referring back to fig. 29, the melting unit 120 includes a hollow pressurized cartridge 121 configured to contain the polymeric material and having a first pressure, and the mixing unit 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, to prevent backflow, the first pressure is greater than the second pressure. In some embodiments, the polymeric material is drawn from the melting unit 120 to the mixing unit 130 by a difference between the first pressure and the second pressure.

The foaming agent supply unit 140 is connected to the mixing unit 130, and is configured to deliver the foaming agent into the mixing unit 130. In some embodiments, the blowing agent supply unit 140 is located between the first flow control element 161 and the second flow control element 162. In some embodiments, the blowing agent supply unit 140 is disposed proximate to the first flow control element 161 and distal to the second flow control assembly 162.

In some embodiments, a blowing agent source (not shown) is connected to blowing agent supply unit 140 and is configured to supply any type of blowing agent known to those skilled in the art. In some embodiments, the foaming agent is in a supercritical fluid state after being introduced into the mixing unit 130 by the foaming agent supply unit 140.

In some embodiments, the first flow control assembly 161 is disposed at a first interface 171 that connects the melting unit 120 to the mixing unit 130. The first interface 171 is configured to direct the polymeric material from the melting unit 120 to the mixing unit 130. The first interface 171 is located between the melting unit 120 and the mixing unit 130. In some embodiments, the first interface 171 is configured to direct polymeric material from the pressurized cartridge 121 of the melting unit 120 into the mixing cartridge 131 of the mixing unit 130. In some embodiments, the difference between the first pressure and the second pressure is utilized to transport and/or draw polymeric material from the melting unit 120 through the first interface 171 and toward the mixing unit 130.

In some embodiments, the first flow control assembly 161 is disposed between the melting unit 120 and the mixing unit 130 and is configured to control the flow of the polymeric material from the melting unit 120 to the mixing unit 130. The first flow control element 161 may be a valve, a movable cap, or the like.

In some embodiments, the first flow control assembly 161 is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element 161 allows polymeric material to flow from the melting unit 120 into the mixing unit 130, and the closed configuration of the first flow control element 161 prevents polymeric material from flowing back from the mixing unit 130 to the melting unit 120.

In some embodiments, the first flow control assembly 161 is configured to maintain a pressure differential between the melting unit 120 and the mixing unit 130. In some embodiments, the first flow control assembly 161 is configured to maintain a pressure differential between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration such that the polymeric material cannot flow from the mixing cartridge 131 of the mixing unit 130 back to the pressurized cartridge 121 of the melting unit 120. In some embodiments, the first flow control assembly 161 is configured to regulate the first pressure and/or the second pressure to maintain a pressure differential between the first pressure and the second pressure. In some embodiments, the first flow control element 161 is in a closed configuration when the first pressure is similar to the second pressure.

In some embodiments, the injection unit 150 is configured to receive the mixture discharged from the second discharge channel 133 of the mixing unit 130 and discharge the mixture from the injection unit 150. In some embodiments, the injection unit 150 is configured to inject the mixture, and the discharge passage 50 is in communication with the injection unit 150.

In some embodiments, the injection unit 150 includes a hollow metering cartridge 151 configured to hold the mixture. The metering cartridge 151 has a hollow interior space 1511, wherein the interior space 1511 communicates with the second discharge channel 133 and is configured to contain the mixture. The injection unit 150 further includes a connection passage 152 communicating with the inner space 1511 of the metering box 151; and a discharge member 153 slidably disposed in the interior space 1511 of the metering box 151 and configured to discharge the mixture from the metering box 151 through the outlet 154.

In some embodiments, the mixture flows from the injection unit 150 into the discharge passage 50. In some embodiments, the mixture is the first material M1 and/or the second material M2.

One aspect of the present disclosure relates to an article. The article includes: a foam member comprising a polymeric material; and a core embedded in the foaming member; wherein the core includes a first surface, a second surface opposite to the first surface, and a sidewall between the first surface and the second surface, the foaming member covering at least a portion of the first surface and covering the entire sidewall and the entire second surface.

In some embodiments, the core includes a through-hole extending between the first surface and the second surface. In some embodiments, a recess is recessed into the core and disposed at the first surface, the second surface, or the sidewall. In some embodiments, the core includes a protrusion protruding from the first surface, the second surface, or the sidewall, and the protrusion is surrounded by the foaming member. In some embodiments, the article further comprises a component disposed on the core and the foaming member, and a portion of the foaming member is disposed between the component and the core. In some embodiments, the core is surrounded by the foaming member.

One aspect of the present disclosure relates to a method of manufacturing an article. The method comprises the following steps: providing a molding device, wherein the molding device comprises a first mold, a second mold corresponding to the first mold, and a supporting member protruding from the inner wall; disposing a core on the support member; disposing the second mold over the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member contacts the core.

In some embodiments, the method further comprises retracting the support member into the first mold or removing the support member from the mold cavity during or after injecting the first material. In some embodiments, the method further comprises injecting a second material into the mold cavity after removing or retracting the support member. In some embodiments, the ratio of polymeric material to blowing agent in the first material is substantially equal to the ratio of polymeric material to blowing agent in the second material. In some embodiments, the method further comprises forming a mark on the first foaming member at a position corresponding to the support member. In some embodiments, the method further comprises injecting a gas into the mold cavity prior to injecting the first material to increase the pressure of the mold cavity to a first predetermined pressure. In some embodiments, the method further comprises venting a gas from the mold cavity to reduce the pressure in the mold cavity to a second predetermined pressure. In some embodiments, at least a portion of the first material is disposed in a recess or a through-hole of the core.

In some embodiments, at least a portion of the first material is disposed between the inner wall and the core. In some embodiments, the support member includes a plurality of support cells protruding from the inner wall, and at least a portion of the first material is disposed between the support cells. In some embodiments, the core includes a first surface in contact with the support member, a second surface opposite the first surface, and a sidewall between the first surface and the second surface, the first foam member contacting at least a portion of the first surface and covering the entire sidewall and the entire second surface. In some embodiments, the method further comprises disposing an assembly in an opening of the second mold prior to injecting the first material. In some embodiments, at least a portion of the first material is disposed between the component and the core after the injecting of the first material. In some embodiments, the method further comprises: providing an extrusion system configured to produce the first material and having a melting unit and a mixing unit; and providing a discharge passage in communication with the extrusion system and including an outlet disposed remotely from the extrusion system and configured to discharge the modeling material, wherein a feed inlet of the modeling apparatus is correspondingly engaged with the outlet.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other operations and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Moreover, the scope of the present disclosure is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Description of the symbols:

10. extrusion system

20. 20-1, 20-2, 20-3 articles

21. Core(s)

22. Foaming member

23. Assembly

30. Molding device

32. Second mold

33. First mold

34. Die base

35. Feed inlet

36. Pressure regulating system

37. Supporting member

40. Supporting device

41. First assembly

42. Second assembly

50. Discharge channel

51. An outlet

70. Insulator

100. Injection molding system

120. Melting unit

121. Pressure tray

122. A first feed channel

123. A first discharge passage

124. Pushing component

125. Feed hopper

130. Mixing unit

131. Hollow mixing box

132. The second feed channel

133. Second discharge passage

134. Mixing rotor

140. Blowing agent supply unit

150. Injection unit

151. Hollow metering box

152. Connecting channel

153. Discharge member

154. An outlet

161. First flow control element

162. Second flow control element

171. First interface

180. Monitoring module

211. First surface

212. Second surface

213. Side wall

214. Through hole

215. Concave part

216. Projection part

217. First layer

218. Second layer

221. First foamed member

222. Second foamed member

321. Upper die cavity

331. Lower die cavity

332. Inner wall

333. Inner side wall

334. Inner bottom wall

341. 71, 322 opening

351. Feed opening

352. Guide channel

361. First gas conduit

362. A second gas conduit

363. Gas source

364. First valve

365. Second valve

366. Pressure sensing unit

367. Joint point

371. 372, 373 support unit

374. 375, 376 marking

411 elongated part

412. Arm part

700. Method of producing a composite material

701. 702, 703, 704, 705 operations

1211. 1511 inner space

1212. Inner side wall

1311. Inner side wall

1341. Columnar body

1342. Concave part

Distances D1, D2, D3, D4, D5, D6

G gas

Height of H1 and H2

Length of L1, L2, L3

M1 first Material

M2 second material

Claims (10)

1. An article, comprising:

a foam member comprising a polymeric material; and

a core embedded in the foaming member;

wherein the core includes a first surface, a second surface opposite to the first surface, and a sidewall between the first surface and the second surface, the foaming member covering at least a portion of the first surface and covering the entire sidewall and the entire second surface.

2. The article of claim 1, wherein the core comprises a recess recessed into the core and disposed at the first surface, the second surface, or the sidewall.

3. The article of claim 1, further comprising an assembly disposed over the core and the foaming member, and a portion of the foaming member is disposed between the assembly and the core.

4. The article of claim 1, wherein the core includes a through-hole extending between the first surface and the second surface.

5. The article of claim 1, wherein the core comprises a protrusion protruding from the first surface, second surface, or sidewall, and the protrusion is surrounded by the foaming member.

6. The article of claim 1, wherein the foaming member is co-molded with a mold cavity of a molding apparatus, the mold cavity being defined by a first mold and a second mold.

7. The article of claim 6, wherein the first mold comprises an inner wall and a support member protruding from the inner wall, the support member for contacting the core.

8. A molding apparatus for preparing an article comprising a foaming member and a core, comprising:

a first mold;

a second mold, which can be closed with the first mold; and

a mold cavity defined by the first mold and the second mold, the mold cavity comprising an inner wall of the first mold and a support member protruding from the inner wall;

wherein the mold cavity is configured to receive the foaming member and the core, and the support member is configured to support the core in the mold cavity and prevent the core from contacting the inner wall of the first mold.

9. The molding apparatus of claim 8, further comprising:

a pressure regulating system including a gas conduit connected to the first mold and communicating with the mold cavity.

10. The molding apparatus of claim 9, wherein the gas conduit is adjacent to the support member.

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